Weichenstellung für morgen | Setting the course for tomorro · Corrosion protection class KIII acc. to DIN 55928-8 ZM 250, ZM 310 *) Deutsches Institut für Bautechnik

Stahl-Zentrum

STAHL 2015

1 | 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl

Conserving Resources and increased Cost Effectiveness by using Zinc

Magnesium Coatings

Innovative rolled steel products for the energy transition

Dr. ir. Peter Jongenburger Board Member for the Flat and Tube Business Unit, Wuppermann AG, Leverkusen

Weichenstellung für morgen | Setting the course for tomorrow

Stahl-Zentrum

STAHL 2015


Introduction

• Working Group hosted by Steel Institute VDEh focused on Zinc-Magnesium-

Aluminum coatings (ZM).

• Study was performed on Zinc-Magnesium-Aluminum coatings in the following

composition range:

• Magnesium: [1.0 % - 3.0 %] *)

• Aluminum: [1.0 % - 3.7 %] *)

• Markets for Zinc Magnesium:

• Building industry & Construction industry

• Colour coating industry

• Automotive industry

*) Weight %, Theoretical targets not including technical tolerances.

Stahl-Zentrum

STAHL 2015


Protection of Steel Structures in Civil Construction • ZM coatings are recommended for harsh environments coastal / agricultural / tropical

• ZM coatings allow bare application of metallic coated steels with lower coating weight

than classical hot-dip galvanised

Green Aspects • Less need for zinc: reduction of mining and metallurgical processing

• Reduced maintenance compared to conventional coatings

• No need for replacement of parts

• Reduction of environmental impact

• Less need for separation of steel and zinc in the scrap melting process

Savings along the whole product life cycle: fabrication, serving time and recycling

Stahl-Zentrum

STAHL 2015


Protection of Steel Structures in Civil Construction

Potential of Zinc Savings in case of substitution Z1000 by ZM600

(source: European Market Outlook for Photovoltaics 2014-2018)

Photovoltaic-installation with ZM-profiles in

Austria, Styria

Stahl-Zentrum

STAHL 2015


savings

life

tim

e p

ote

ntia

l

Z coating thickness

Co

rro

sio

n r

esis

tan

ce

in d

ep

en

den

ce o

f th

e lo

ad

[ye

ars

]

Area of Zinc

Area of ZM

standard high highest

Potential for ZM

technical

limit

Corrosion Resistance in dependence on the load by years


Metal savings and/or lifetime potential

Stahl-Zentrum

STAHL 2015


• DIBt *) certifications since 2013

• Corrosion protection class KII acc. to DIN 55928-8

ZM120

• Corrosion protection class KIII acc. to DIN 55928-8

ZM 250, ZM 310

*) Deutsches Institut für Bautechnik

Excellent corrosion protection and high durability are required for these applications


Domestic airport: Dominican Republic

Stahl-Zentrum

STAHL 2015


Organic Coated Steel Sheets

Possible advantages for organic coating:

• Increased corrosion resistance

• Enlarged durability

• Coating weight reduction

Economy and Environment

• Overall cost saving across supply chain

• Reduction of energy consumption in the extraction of raw materials

• Protection of Zinc-resources

Successfully in use for more than 10 years

Stahl-Zentrum

STAHL 2015


Organic Coated Steel Sheets – Reduced coating weight of base material

Conserving resources and increasing cost effectiveness by

using ZM Coatings

ZM140 ( 0,01mm)

Substrate = 0,96mm

ZM140 ( 0,01mm)

ZM140

Possibility of reducing the

thickness to 0.98 mm

0,0%

0,5%

1,0%

1,5%

2,0%

2,5%

3,0%

3,5%

4,0%

4,5%

0,5 1,0 1,5 2,0 2,5 3,0

Are

a A

dva

nta

ge

[%

]

Order Thickness [mm]

Z275 ( 0,02mm)

Substrate = 0,96mm

Z275 ( 0,02mm)

Zinc 275 Overall thickness 1.00 mm

Stahl-Zentrum

STAHL 2015


Organic Coating Steel Sheets - certifications

• DIBt certifications since 2008

• INTERIOR building applications:

Corrosion protection class KII acc. to DIN 55928-8

ZM100 + 15 µm Polyester (alternative to Z275 + 15 µm Polyester)

• OUTER building applications:

Corrosion protection class KIII acc. to DIN 55928-8

ZM 140 + 25 µm Polyester (alternative to Z275 + 25 µm Polyester)

Example of outer building application

Zinc Magnesium coated steel sheet became a standard for organic coated products

Stahl-Zentrum

STAHL 2015


Automotive

Strategic Importance

• Lightweight is often associated with Aluminum

steel solutions were seen as conservative

• Zinc Magnesium coatings significantly improve

corrosion protection, press shop performance and environmental compatibility

• Steel solutions in combination with Zinc Magnesium coatings receive considerable attention

at the customer

Technical benefits

• Thinner coatings at equal corrosion performance

• Reduced frequency of tool cleaning intervals (less zinc particles)

• More robust operating window in the press shop

• Increased production yield (less scrap)

Stahl-Zentrum

STAHL 2015


Automotive

• Zinc Magnesium coating helps to

keep steel in automotive industry

• Zinc Magnesium coating is

becoming a standard for European

automotive

• EN 10346:2015 “Continuously hot-

dip coated steel flat products for

cold forming”: ZM coatings with

1,5 – 8 wt. % (Al + Mg) have been

included ZM

ZM

Wheel

enclosure

Number of manufactured components between two cleaning downtimes

Interior door

component

Classical galvanized steel strip

Classical galvanized steel strip

Excellent formability and

tribological behaviour

Scribe creepage, KTL coated

after 10 weeks, VDA Test 621-415

Scribe creepage, KTL *) coated

after 10 weeks, VDA Test 621-415

Classical galvanized steel Zinc Magnesium coated steel

*) Cathodic dip painting

Stahl-Zentrum

STAHL 2015


Summary

• Excellent corrosion resistance allows savings along the whole product life

• Metal savings and/or increase of life time

• Increasing cost effectiveness by using ZM Coatings

• Less need for zinc implies reduction of mining and metallurgical processing

• Lower run-off into the soil

• Opening new markets

• Zinc Magnesium helps to keep steel in the business and is becoming a standard in

automotive

• Technical approvals for use in various European countries

Stahl-Zentrum

STAHL 2015


THANK YOU FOR YOUR ATTENTION

Innovative rolled steel products for the energy transition

Weichenstellung für morgen | Setting the course for tomorrow

Dr. ir. Peter Jongenburger Board Member for the Flat and Tube Business Unit, Wuppermann AG, Leverkusen

Documents

Weichenstellung für morgen | Setting the course for tomorro · Corrosion protection class KIII acc. to DIN 55928-8 ZM 250, ZM 310 *) Deutsches Institut für Bautechnik